Foundry flask construction



Dec. 11, 1956 W. G. REICHERT FOUNDRY FLASK CONSTRUCTION 2 Sheets-Sheet 1 Filed Aug. 13, 1954 Dec. 11, 1956 w. G. Rr-:lcHERT FOUNDRY FLASK CONSTRUCTION 2 Sheets-Sheet 2 Filed Aug. 13; 1954 M moi v w INVENTOR /VZ//iam @fe/'cheff BY GATTORN EY United States Patent O F OUNDRY FLASK CONSTRUCTION William G. Reichert, Newark, N. J.

Application August 13, 1954, Serial No. 449,653

Claims. (Cl. 22-101) This invention relates to a foundry flask construction for casting soil pipe and similar tubular cast products.

It is an object of the present invention to provide a ilask construction having openings in the opposite end walls thereof whereby after the soil pipe has been cast in the ilask the arbors or core which form the hollow opening through the soil pipe may be removed from the flask by driving the arbor longitudinally outwardly through one of the openings in the end walls of the flask.

Another object is to provide a mold ilask construction of the character described and comprising a llask section,

which may be either a cope section or a drag section, hav- `ing notches or recesses in the opposite end walls thereof, .a pattern plate adapted to be secured to the llask section '.to form an impression in the molding sand which is `rammed into the flask section, and end cover plates seicured to opposite ends of the pattern plate for closing off said notches or recesses in the ilask section end walls :so as to prevent the molding sand within the flask section from flowing through said openings as the sand is poured :and rammed therein.

A further object of the invention is to provide a novel :arrangement for mounting the pattern plate to the flask :section and comprising a dish plate having a recessed suriface for mountably receiving the pattern plate, means to :secure the pattern plate in assembled relation with respect to the dish plate and to prevent relative movement of :said plates, and means on the dish plate for accurately :aligning the two plates in assembled relation with respect to the ilask section.

Another object is to provide a foundry ilask comprising a pair of vertical side walls and a pair of vertical end walls joined thereto to form a substantially rectangular frame open at the top and bottom, said end walls each being formed with an opening therethrough extending throughout a major portion of the area thereof.

A further object is to provide a ilask section construction comprising a pair of vertical side walls and a pair of vertical end walls joined thereto to form a substantially rectangular frame open at the top and bottom, said end walls each being formed with an opening therethrough extending throughout a major portion of the area thereof, a pattern plate, a pair of cover plates each secured to one of the opposite ends of the pattern plate, means for maintaining the pattern plate in assembled relation to the flask section, said cover plates having a shape conforming to the shape of the openings in the tlask end walls and closing olf said openings when the pattern plate is in assembled relation to the flask section.

Another object is to provide a pattern plate comprising a horizontal planar base portion, a plurality of longitudinal horizontally-extending parallel semi-cylindrical portions projecting upwardly from the upper surface of saidl base portion, and a pair of cover plates secured to the opposite ends of said pattern plate and extending vertically `in planes perpendicular to the axes of said semicylindrical portions. i

Still another object of the invention is to provide a novel flask construction of the character described and which is particularly adapted for use in the novel casting apparatus and method as disclosed in my copending application Serial Number 449,656 filed August 13, 1954.

Other objects and advantages of the present invention are inherent in the structure as disclosed and claimed or will become apparent to those skilled in the art as the description proceeds in connection with the accompanying drawings wherein:

Fig. 1 is a plan View of a flask section with a pattern plate and dish plate assembled thereto in accordance with a preferred embodiment of the present invention, the flask section being broken away;

Fig. 2 is a side elevational view of the combination shown in Figure 1, and is partially in section;

Fig. 3 is a transverse sectional view taken on line 3 3 of Fig. 1;

Fig. 4 is a transverse sectional view showing two llask sections joined together in assembled relation forming a ilaskin preparation for the molding operation, the molding sand having been rammed into the ilasks and the pattern plate and dish plate removed. therefrom;

Fig. 5 is a partial sectional view showing the dish plate with the pattern plate assembled therein, the section being taken perpendicular to the end wall of the pattern plate;

Fig. 6 is a sectional view of the flask section on line 6-6 of Figure 1 but shows the pattern plate and dish plate removed from the ilask section;

Fig. 7 is an end elevational View of the construction shown in Fig. 1;

Fig. 8 is an end elevational view of a dish plate and pattern plate assembled thereto for use in casting two pipes of four inch size as distinct from the embodiment shown in Figures l to 7 wherein the pattern plate is constructed for casting three pipes of three inch size; and

Fig. 9 is an end elevational view similar to Fig. 8 but showing a pattern plate adapted for casting four pipes of two inch size.

Referring now to the drawing in more detail, the reference numeral 11 indicates generally a ilask construction in accordance with the present invention and comprising a flask section 12, a dish plate 33, and a pattern plate 34. Although the term flaskforiginally was applied to a combined assembly of a cope and a drag, the term flask section is now frequently applied to indicate either the cope or the drag itself and is so employed throughout this specification and the claims appendedu hereto. That is, the cope and drag in accordance with the present invention are substantially identical and hence when the term` flask section is used, it is toV be under,- stood that either a cope or a drag is meant'by this termi The llask section 12 comprises a pair of side walls 13, 14 joined to a pair of oppositely disposed end walls 15, 16. The walls 13, 14, 15 and 16 of ilask section 12 thus form a substantially rectangular frame-like structure open at its top and bottom sides. As best seen in Figures 3 and 6, the walls 13 to 16 are formed with integral in- Wardly-projecting ilange portions 17, 18 along their upper edges. The lower edges of walls 13 to 16 are formed with similar inwardly-projecting flange portions 19, 20.

These designations of the Wall edges as upper and lower will of course be reversed if the, flask section 12 is considered to be a drag rather than a cope. The flanges 17, 18 extend in a continuous integral fashion around area which abuts against a corresponding parting plane surface on another similar flask section joined thereto to form a complete assembled cope-and-drag combination as shown in Figure 4.

A pair of longitudinal ribs 23, 24 each extend along the exterior surface of one of the ask side walls 13, 14. respectively. The ribs 23, 24 serve torigidify yask section 12 and also provide means for engagement by an unstacking device (not shown) whichV lifts thev cope upwardly olf the drag, as will be understood by those skilled in the art. A pair of lugs 25', 2a and27, 23 'are formed integral with each of the side walls.13, adjacent the opposite ends of flask section 12. Each of the lugs 25 to 28 is provided with a vertically extending hollow sleeve 29.

As shown in Figure 6, end walls 16 are each'provided with a longitudinal brace member tisecuredthcreto as by welding at 31,' 31. A tru'nnion 32-is weldedfto brace element 3)v at 35 on each of the side walls 15 and `16, lboth trunnions 32 being in alignment/along the longitudinal center line of flask 12. The trunnions 32,` provide a means for indexing the ask into the' molding machine by the measuring box of the molding machine as illustrated in my co-pending application filed on even date herewith, Ser. No. 449,656, as well asa means by which the ask 12 may be rot-ated and inverted.

Both opposite end walls 15, 16 of' flask section 12'are provided with a notch or recess '35i extending fromv the parting plane surface 22 to a horizontally-extendingsubstantially straight t-op edge .portion 36. The edgelof notch or recess 35 extends arcuately at 37, 3S from the .opposite ends of the straight edge portion 36, toward the parting plane surface 22. Extending-'along the edges 36, 37,38 of notch or recess 35 is a flange elementj39 'secured to the inner surface 4t) of eachof the end walls 15, 16 thereby strengthening and rigidifyingv the latter. The flange element 39 also acts as a support for the molding sand which is squeezed in the flask.

The dish plate 33 comprises a flat horizontal base portion 41. Integral with the side edges ofthe latter and extending upwardly therefrom are a pair of side walls 42, 43. Secured to the upper' surface 44 of base portion 41 are a pair Vof retainer bars 45 substantially rectangular in cross-section, each of the bars 45 extending along one of the'ends of dish plate 33. Screws 46 serve to secure retainer bars 45 to base portion 41. The upper surface 47 of each bar 45 is substantially co-planar with the upper surfaces 48 of the side walls 42, 43.

'Side wall 32 is provided with a pair of lugs 49 adapted to be aligned with lugs 25, 26 of flask side wall 13 and side wall 43 is similarly provided with a pair of lugs 5t) adapted to be aligned with lugs 27, 23 respectively of flask side wall 14. Press-fitted within a suitable aperture provided within each of the four lugs 49, 50 is a pin 51 extending upwardly therefrom and having a tapered portion 52. Pins 51 are adapted to enter the bushings 29 in lugs ste 28 so as to maintain the dish plate 33 and pattern plate `34 in correct alignment with ask 12 when assembled thereto.

Y Pattern plate 34 comprises a substantially planar base portion 75 of rectangular shape. Integral with base portion 75 `and extending upwardly from the upper surface 76 thereof are three longitudinal portions 77, 78, 79 o-f semi-cylindrical configuration and having adjacent the opposite ends thereof enlarged shoulder portions 77', 78', 79' respectively. The latter form the impressions in the molding sand for casting the enlarged end portions of the soil pipes and are provided with enlarged semi-cylindrical flangeportions 77, 73,y 79 respectively. The latter `form impressions in the molding sand for the end flanges of the soilpipes. Outwardly'of liange portions 77, '78, 79 the opposite end of each of the semi-cylindrical. pattern portions 77, 78, 79 comprises semi-cylindrical core prints 50a, 51a, 52a for forming the impressions within which the arbor core is supported in the mold du-ring the castmg operation.

The lower surface 53 of pattern plate basey portion 75 rests upon the upper surface 44 of base portion 41 of dish plate 33. Pattern plate base portion is provided with.. vertical end walls 54 at opposite sides thereof. The end walls of the semi-cylindrical portions 77, 73, 79 extend an-gularly outwardly as at 55 in Figure 5. Secured to the end walls 55 are a pair of cover plates 56 each having an inner surface 57 angularly inclined so as to abut ush against walls 55 and are maintained in engagement therewith by screws 58 extending through cover plates 56. As shown in Figure 7, there are three screws 58 engaging each of the pattern portions 77, 7S, 79. lt will now be observed that the notches or recesses 35 have portions which are offset from or extend beyond the ends of portions 77, 7S, 79 o-f the pattern plate 34 so that sand would fall out of said notches or recesses except for the fact that the cover members 56 prevent the sand from pouring or fallin-g out of the ask section.

The lower surface 59 of each cover plate 56 rests upon the upper surface 47 of the respective retainer bar 45. The end surface 54 of pattern plate base portion 75 abuts against the inner surface titi of retainer bar 45. It will thus be seen that pattern plate 34 with cover plates 56 secured thereto may be placed in assembled relation within dish plate 33. ln order to maintain dish plate 33 and pattern plate 34 in properly aligned relation with respect to each other, a pair of pins 61, 62 are press-fitted within suitable apertures provided in dish plate base portion 41 and exten-d upwardly therefrom to engage within hol-es formed in the lower surface of pattern plate base portion 75. A plurality of screws 63 are also provided to secure pattern plate base portion 75 to dish plate base portion 41.

Referring now to Figure S, there is shown a dish plate 33 identical to that shown in Figures l to 7 and described above. Assembled to dish plate 33 is a pattern plate 134 simi-lar to pattern plate 34 described above except that itv is adapted to form impressions in the molding sand for casting two lengths of fou-r inch diameter pipe rather than the three lengths of three inch diameter pipe provided by the impressions of pattern plate 34. Otherwise, pat tern plate 134 is similar to pattern plate 34 and will not be further described, it being obvious that there are only two semi-cylindrical pattern portions 135, 136 on pattern plate 134 and of somewhat larger diameter than pattern portions 77, 73, 79 of pattern plate 34.

In Figure 9 there is shown a dish plate 33 in assembled relation with a pattern plate 234 similar to pattern plate 34 but havin-g four semi-cylindrical pattern portions 235, 236, 237 and 233 of a size for casting pipe of two inch diameter. Except for the number of semi-cylindrical pattern portions and their diameters pattern plate 234 is otherwise identical to pattern plate 34.

Each of the cover plates 56 is provided with an edge having a straight portion 64 and curved portions 65, 66.

- Edge portionsI 64, 65, 66 conform respectively to the edges 36, 37, 38 of notches or recesses 35 formed in the end walls 15, 16 of ask 12.

It will thus be seen that when dish plate 33 and'pattern plate 34 are assembled to flask 12, cover plates 56 will extend through the area of notches or recesses 35 so as to close the latter and prevent molding sand from owing therethrough.

The mode of operation of flask construction 11v will now be briefly described. Dish plate 33 with pattern plate 34 secured thereto is placed in assembled relation with respect to flask 12. The lower parting plane surfaces 22 of flask 12 will abut against the upper surfaces 48 of dish plate side walls 42, the upper surfaces 47 of retainer bars 45 and also the upper surface 76 of pattern plate base portion 75. Pins 52 will enter bushings 29 so as to guide flask section 12 and dish plate 33 with respect to each other and thereby maintain flask section 12 in accurate alignment with respect to pattern plate 34 which has previously been secured to dish plate 33.

Molding sand indicated by the reference letter S is then poured into flask section 12 and rammedj in any suitable manner. The semi-cylindrical pattern portions 77, 78, 79 will thus form semi-cylindrical impressions in the molding sand. Pattern plate 34 and dish plate 33 are then removed from llask section 12. The above operation is carried out for a pair of flask sections 12 so as to provide an identical cope and drag which may then be assembled together to form a complete flask box as shown in Figure 4. In this ligure, the reference numeral 12 indicates 'the llask section heretofore described with the dish plate 33 and pattern plate 34 removed therefrom after the molding sand S has been poured and rammed therein to form the longitudinal semi-cylindrical impressions indicated at I. The reference numeral 112 indicates ano-ther tlask section similar to tlask section 12. The latter may act as the cope and flask section 112 may serve as the drag, or these functions may be reversed by merely inverting the assembled flask box. The parting plane surface 22 of flask section 12 abuts against the parting plane surface 122 of tlask section 112 and the two llasks are maintained in properly aligned assembled relationship by means of the lugs 25 to 2S on flask section 12 and the corresponding lugs 113 on flask section 112, in the manner `well-known in the art.

The semi-cylindrical impressions I in the molding sand within flask section 112 thus cooperate with the impressions I in flask section 12 to form longitudinal cylindrical impressions into which the molten casting metal llows to form the soil pipes after insertion of cores into the mold cavity before casting. After the soil pipes have been thus cast, the arborcores (not shown) which form the hollow openings through the pipes are moved longitudinally endwise through the openings 35, 135 formed in the end walls of flask sections 12, 112. The exterior surfaces of the arbor cores are formed of core sand which crumples as the arbor cores are removed longitudinally outwardly through notches or recesses 35, 135 thereby enabling the cores to be moved axially through the hollow interiors of the cast soil pipes notwithstanding the undercuts on the interior Wall surfaces of the pipes.

It will thus be seen that the notches or recesses 35, 135 formed in the end walls of each ilask section enable the arbor cores to be quickly and easily removed from the cast soil pipes before the latter are removed from the flask box. By providing the pattern plate 34 with the end cover plates 56, the notches or recesses 35, 135 are closed so as to prevent the molding sand from flowing outwardly therethrough as the sand is being poured and rammed into the llask sections 12, 112.

It is to be understood that the specific embodiments shown in the drawing and described above are merely illustrative of several of the many different forms which the invention may take in practice without departing from the scope of the invention as delineated in the appended claims.

Having thus described the invention, what is claimed is:

l. A flask section construction comprising a flask having a pair of vertical side walls and a pair of vertical end walls joined thereto to form a substantially rectangular frame open at the top and bottom, said end walls each being formed with notches in the lower edges thereof, a pattern plate, a pair of cover plates each secured to one of the opposite ends of the pattern plate, means for maintaining the pattern plate in assembled relation to the flask section, said cover plates having a shape conforming to the shape of said notches in the flask section end walls and closing olf said notches when the pattern plate is in assembled relation to the flask section, and said pattern plate being formed with longitudinal pattern portions extending to said cover plates.

2. A flask section construction comprising a flask having a pair of vertical side walls and a pair of vertical end walls joined thereto to form a substantially rectangular frame open at the top and bottom, said end walls each being formed with a notch in an edge thereof,

a pattern plate closing the bottom of the llask section, a pair of cover plates secured to the opposite ends of the pattern plate and received in said notches, a dish plate having a recessed portion engageably receiving said pattern plate, co-acting means on said llask section and said dish plate for maintaining the dish plate with the pattern plate engaged therewith in properly aligned assembled relation to said ilask section.

3. A flask section construction comprising a llask hav ing a pair of vertical longitudinal side walls and a pair ot' vertical end walls joined thereto to form a substantially rectangular frame open at the top and bottom,said end walls each being formed with a notch in the lower edge thereof, a pattern plate comprising a horizontal planar base portion, a plurality of longitudinal horizontally-extending parallel semi-cylindrical portions projecting upwardly from the upper surface of said base portion, and a pair of cover plates secured to the opposite ends of said pattern plate and extending vertically in planes perpendicular to said semi-cylindrical portions, means for maintaining the pattern plate in assembled relation to the flask section, said cover plates having a shape conforming to the shape of the notches in the flask section end walls and received in and closing olf said notches when the pattern plate is in assembled relation to the flask section.

4. A flask section construction comprising a flask having a pair of vertical longitudinal side walls and a pair of vertical end walls joined thereto to form a substantially rectangular frame open at the top and bottom, said end walls each being formed with notches in the lower edges thereof, a pattern plate comprising a horizontal planar base portion, a plurality of longitudinal horizontally-extending parallel semi-cylindrical portions projecting upwardly from the upper surface of said base portion, and a pair of cover plates secured to the opposite ends of said pattern plate and extending vertically in planes perpendicular to said semi-cylindrical portions, a dish plate comprising a planar horizontal base portion and vertical wall portions extending upwardly from the peripheral edges of said base portion, said pattern plate base portion resting upon the upper surface of said dish plate base portion and interlitting between said dish plate wall portions, means for maintaining said pattern plate and said dish plate in aligned secured relation, and means on said dish plate for securing the latter with the pattern plate secured thereto in aligned assembled relation to said flask section, said cover plates having a shape conforming to the shape of the notches in the flask section end walls and received in and closing off said notches when the pattern plate is in assembled relation to the flask section.

5. A ilask section construction comprising a flask having a pair of vertical side Walls and a pair of vertical end walls joined thereto to form a substantially rectangular frame open at the top and bottom, said end walls each being formed with a notch in an edge thereof, a pattern plate comprising a horizontal planar base portion, a plurality of longitudinal horizontally-extending para-llel semi-cylindrical portions projecting upwardly from the upper surface of said base portion, and a pair of cover plates secured to the opposite ends of said pattern plate and extending vertically in planes perpendicular to said semicylindrical portions, a dish plate having a recessed portion engageably receiving said pattern plate, co-acting means on said flask section and said dish plate for maintaining the dish plate with the pattern plate engaged therewith in aligned assembled relation to said flask section, said cover plates having a shape conforming to the shape of the notches in the flask `section end walls and received in and closing olf said openings when the pattern plate is in assembled relation to the llask section.

6. In combination, a flask section having an end wall formed with a notch in an edge thereof, a pattern plate '2' secured to said ilask section, and a coverplate `secured, to 'one end of the pattern plate yandaligned,withsai-d end Wall'. notch and received in and closing the latter to prevent sand flowing therethrough.

7; In combination, a flask section having an end wall formed with a notch in an edge thereof, a pattern plate secured to said flask section, and a cover plate secured to one end of the pattern plate and aligned with said end wall notch and closing and received in the latter to prevent sand llowing therethrough, said pattern plate having a longitudinal pattern means for forming an impression in molding sand, said longitudinal pattern means extending in a direction perpendicular to said cover plate and being overlapped by said cover plate.

8. In combination, a ask section having a pair of opposite end walls each'with a notch in an edge thereof, a pattern plate secured to said ask section, and a pair of cover plates secured to opposite ends of the pattern plate. and aligned with said end'wall notches respectively and closing the latter to prevent sand flowing therethrough.

9. In combination, a ask section having a pair of opposite end walls each with a notch in an edge thereof, a pattern plate secured to said flask section, and a pair of cover plates secured to opposite ends of the pattern plate and aligned'with said end wall notches respectively and ciosing. the latter to prevent sand ilowing therethrough, said pattern plate having longitudinally-extending pattern means for forming impressions in molding sand, Ysaid pattern means extending in a direction perpendicular to said cover plates, the latter abutting the opposite ends of said pattern means.

10. A foundry ask section comprising a pair of vertical vlongitudinal side walls and a pair of vertical end Walls joined thereto to form `a substantially rectangular frame open at the top and bottom, said end walls each being lformed with a notch in an edge thereof, said notches being aligned, a dish plate covering the frame and l0- cated at the notched edges of the end Walls, a pattern plate on said dish plate, said pattern plate comprising elongated, longitudinal pattern portions extending from one end wall to the other end wall and parallel to the side walls, said notches having portions overlapping the ends of said longitudinal portions of the pattern plate and portions offset from the ends of said longitudinal portions of the pattern plate, and cover members fixed to the lli) pattern plate covering the ends of said longitudinalpor.- tions of said pattern plate, `and closing lsaid notches so as to prevent sand poured into the ask section from pouring out through said notches.

11. The combination of claim 10, and means to pin the dish plate to the ask section.

l2. The combination of claim 1l, and means to pin said pattern plate to the dish plate.

13. The combination of claim 1.0, said asksection having apertured lugs extending outwardly therefrom, dish plate having lugs extending outwardly therefro pins thereon projecting into the apertures formed in the lugs on the flask section, to align the dish plate with the flask section.

14. The combination of claim 13, said dish plate contacting said flask section and having a depression receiving said pattern plate and said flask section having portions contacting an upper surface of said pattern plate.

15. A flask section comprising a pair of opposite side walls and a pair of opposite end walls and being opened at the top and bottom, one of said walls being formed with a notch in an edge thereof, a pattern plate covering one open'end of the llask, said pattern plate being provided with a pattern portion having an end extending to said notch, and said notch having a portion overlapping said end of said pattern portion and having aportion otfset from said end of said pattern portion, and a cover member on said pattern plate closing the notch and contacting said end of said pattern` portion to prevent sand poured into the flask from pouring out of said notch.

References Cited in the le of this patent UNITED STATES PATENTS 88,020 Edson Mar. 23,.1869 438,137 Barrett Oct. 14, 1890 451,237 Stader Apr. 28, 1891 525,355 Neff Sept. 4,A 1894 574,748 Moore Jan. 5, 1897 586,241 Moore July 13, 1897 709,768 Hodges Sept. 23, 1902 V936,081 Blue Oct. 5, 1909 1,291,607 Nelson a n Jan. 14, 1919 2,219,012 Kirby Oct. 22, 1940 2,394,394 Miller Feb. 5, 1946 2,460,213 Capps Jan. 25, 1949 

